Apparatus for manufacturing film cartridge and for feeding plate material

ABSTRACT

A film cartridge assembling apparatus including one or more assembly chucks each including two die elements formed by combining partial cylindrical inner surfaces thereof together. The circumference of a resulting cylinder being partially cut to form an opening. One of the die elements includes a member having a flat surface extending from an end of the cylindrically-shaped inner surface towards the opening. The member is adjustably mounted to the one of the die elements The assembly chuck is able to assume a closed state in which the two inner surfaces of the two die elements are matched to each other to form a cylindrical inner surface and an opened state in which ends of the two die elements substantially parallel to the center axis of the cylindrical inner surface are spaced apart form each other.

This is a divisional of application Ser. No. 11/193,331 filed Aug. 1,2005, which is a divisional of application Ser. No. 10/387,323 filedMar. 13, 2003; the entire disclosures of which are considered part ofthe disclosure of the accompanying divisional application and areincorporated by reference.

FIELD OF THE INVENTION

In a first aspect, this invention relates to a method and apparatus formanufacturing a film cartridge for holding a photographic roll filmtherein, and to a method and apparatus for supplying a plate material.More particularly, it relates to a method and apparatus formanufacturing a film cartridge, whereby a high-speed operation untilforming a one-capped cartridge may be achieved, and to a method andapparatus for supplying a plate material.

In a second aspect, this invention also relates to an apparatus forassembling a film cartridge comprised of a ribbon plate for holding aphotographic roll film therein, and a cap, and to an apparatus forassembling a film cartridge having an assembly chuck for holding theribbon plate in a rounded state.

In a third aspect, this invention further relates to an apparatus forforming a film cartridge by rounding a ribbon plate of the filmcartridge holding a photographic roll film therein.

BACKGROUND OF THE INVENTION

A 35 mm photographic roll film is used in a state in which the film ishoused in a film cartridge. This film cartridge is basically made up bya cylindrically-shaped ribbon plate, a spool housed within the ribbonplate, and caps for closing the upper and lower ends of the ribbonplate. On the inner surface of an end of a film pull-out opening of theribbon plate, there is bonded a velvet ribbon for light shielding.

The method for manufacturing a film cartridge for housing a photographicroll film is now explained. Referring to FIG. 5, for forming theaforementioned ribbon plate for the film cartridge, a metal sheet is cutto a longitudinal size and a transverse size corresponding to thelongitudinal size and the transverse size of a developed ribbon plate,forming the so cut metal sheet so that the cross-sectional shape alongthe long axis of the formed product is in a boat-like shape. To left andright ends of a so formed metal sheet 101 are stuck velvet ribbons 102a, 102 b to produce a so-called boat-shaped ribbon plate.

The boat-shaped ribbon plate then is rounded in a cylindrical shape anda cap 103 a is clinched to one side end of the rounded ribbon plate tofrom a so-called “film cartridge opened on its one side end or aone-capped cartridge” (see FIG. 5).

Finally, an assembly comprised of a film of a predetermined length 105is wound on a spool 104 is inserted from an opening side of theone-capped cartridge, and a cap 103 b is clinched to the open side endof the one-capped cartridge to form a so-called [wound film cartridge]which is a film cartridge having a photographic roll film wound thereon(see FIG. 5).

Referring to the drawings, a conventional method and apparatus formanufacturing a film cartridge are now explained.

Referring to FIG. 6, this conventional apparatus 100 includes an indexunit 170 rotatable about an rotation axis perpendicular to asubstantially horizontal surface and which holds plural assembly chucks171 at equi-angular intervals about the rotation axis. At presetpositions of eight stations, arranged on the circumference of the indexunit 170, there are arranged a ribbon plate supplying unit 110, aone-capped cartridge producing unit 120, a inspecting unit 130, aunacceptable product discharging unit 140, an acceptable productdischarging unit 150 and a remnant discharging unit 160. First, theboat-shaped ribbon plate is inserted (supplied) from the ribbon platesupplying unit 110 into an assembly chuck 171 which may be halted in itsproximity and which is capable of accepting the ribbon plate (see FIG.6). As the index unit 170 is run in rotation, the inserted boat-shapedribbon plate is transported to the one-capped cartridge producing unit120. In this one-capped cartridge producing unit 120, the boat-shapedribbon plate is rounded to a cylindrical shape, and a cap, supplied toone end of the rounded ribbon plate, is inserted and subsequentlyclinched to the ribbon plate to form a one-capped cartridge. As theindex unit 170 is run in rotation, the so formed one-capped cartridge istransported to the inspecting unit 130. In this inspecting unit 130, thestate of engagement between the cap and the ribbon plate in theone-capped cartridge is monitored to detect whether or not theone-capped cartridge is acceptable. As the index unit 170 is further runin rotation, the one-capped cartridge, detected as described above, istransported to the unacceptable product discharging unit 140. If theone-capped cartridge has been found to be unacceptable in the inspectingunit 130, the unacceptable one-capped cartridge is discharged by theunacceptable product discharging unit 140. If conversely the one-cappedcartridge has been found to be acceptable, the one-capped cartridge isnot discharged (see FIG. 6). If, as the index unit 170 is further run inrotation, the one-capped cartridge, found as being acceptable, istransported to the acceptable product discharging unit 150, theone-capped cartridge, verified to be acceptable in the inspecting unit130, is discharged in the acceptable product discharging unit 150 (seeFIG. 6). If the index unit 170 further run in rotation, and any productthat remained without being discharged by the unacceptable productdischarging unit 140 or by the acceptable product discharging unit 150has been transported to the remnant discharging unit 160, such remnant,present in the assembly chuck in the remnant discharging unit 160, isdischarged (see FIG. 6). The index unit 170 is further run in rotationand a boat-shaped ribbon plate is again introduced into the now voidassembly chucks 171 to repeat the above-described processing. Theoperations in the respective process step units are carried outsimultaneously such that one one-capped cartridge is completed for eachpitch of rotation of the index unit.

The ribbon plate supplying unit is explained in detail. The ribbon platesupplying unit may be sub-divided into a ribbon plate transfer processfor transferring a ribbon plate to a stocker (stock unit) from a trayloaded with plural ribbon plates, and a ribbon plate supplying processfor supplying the ribbon plates accumulated in the stocker to the indexunit.

Referring to FIGS. 7 and 8, a ribbon plate transfer process 201 of theribbon plate supplying unit includes a tray changer 210, a transfer unit220 and a stocker 230.

The ribbon plate transfer process 201 delivers a tray 204, on which areloaded plural boat-shaped ribbon plates, aligned in an upstandingposition thereon, by the tray changer 210 (see FIG. 7). That is, afterlifting the second tray from the bottom of a stack of trays, loaded on atray pull down unit 211, the lowermost tray 204 is moved on a conveyorto a transfer unit 212 (see FIGS. 7 and 8). The transfer mechanism 220,including a suction magnet, not shown, enclosed therein, and alsoincluding gripper 221, for gripping the boat-shaped ribbon plate 203with claws, not shown, descends onto the tray 204 on the transfer unit212 to grip together a pre-set number of the boat-shaped ribbon plates203 placed on the tray 204 in the upstanding position. The transfermechanism 220 is then uplifted, as it grips the boat-shaped ribbonplates 203, and then is moved horizontally to a position above thestocker 230 (see FIGS. 7 and 8). The bottom surface of the gripper 221holding the boat-shaped ribbon plates 203 is then tilted, by movement ofa rotation mechanism 222, from a horizontal position to the same angleas that of an inclined base 231 of the stocker 230. The boat-shapedribbon plates 203 are then lowered, in the tilted state, onto theinclined base 231. The gripping of the transfer mechanism 220 is thenreleased. This transfers the set of the boat-shaped ribbon plate 203 inthe upstanding and aligned state to the stocker 230 (see FIG. 7).Meanwhile, the tray 204, now emptied, are sent by a conveyor to a traypile up unit 213. The trays, already existing, are uplifted and theempty tray 204 is inserted in the lowermost tier (see FIGS. 7 and 8).

Referring to FIGS. 9 and 10, the ribbon plate supply process 202 of theribbon plate supply unit includes a stocker 230, a suction mechanism240, a magnet 250 and an assembly chuck 171.

In the ribbon plate supply process 202 of the ribbon plate supply unit,the set of the boat-shaped ribbon plate 203, transferred onto thestocker 230, are slid together by a slide mechanism (stacker weight)towards a lower side, as the boat-shaped ribbon plates 203 are alignedin the upstanding orientation on the inclined base 231, until theboat-shaped ribbon plates 203 are retained by claws, not shown, arrangedin a outlet 232 (see FIG. 9). At this time, the boat-shaped ribbonplates 203, accumulated in the aligned state on the stocker 230, areprogressively transferred from the upstanding aligned orientation to thehorizontal orientation as they move from the inclined base 231 to theoutlet 232 (see FIG. 9). The boat-shaped ribbon plate 203, lying in theoutlet 232 of the stocker 230, are sucked by a suction mechanism 240,which have been lifted by an uplifting mechanism 242, and are therebypulled downwards (see FIG. 9). The boat-shaped ribbon plate 203, thusseparated from the succeeding boat-shaped ribbon plates 203, is pushedtowards right in the drawing, by a claw 261 provided on an swingingmember 260, and is thereby taken out, as the boat-shaped ribbon plate203 remains in the sucked state (see FIG. 9). A baffle board, not shown,is provided at the outlet 232, to prevent two plates from being takenout simultaneously to enable only one plate to be taken out reliablyeach time. The boat-shaped ribbon plate 203, thus taken out, istransported in the sucked state to a position below the magnet 250 andis lifted by an uplifting mechanism 242. The sucked state is thenreleased to permit the boat-shaped ribbon plate 203 to be retained bythe magnet 250 (see FIGS. 9 and 10). The boat-shaped ribbon plate 203,thus retained by the magnet 250, is slid in the next operating cycle bya claw 262 formed on the swinging member 260, so as to be transported tothe assembly chucks 171 of the index unit (see FIG. 10)

The film cartridge assembling device also rounds the ribbon plate,formed to a boat shape, to a cylindrical shape, introduces a cap to oneside end of the rounded ribbon plate, and clinches the cap to the ribbonplate, to assemble the one-capped cartridge. The film cartridgeassembling device includes an assembly chuck for detachably holding theribbon plate for transporting the ribbon plate to the respective processas the ribbon plate is kept to a predetermined shape.

In a certain conventional assembly chuck, shown in FIG. 18, a ribbonplate 550, bent substantially to a cylindrical shape, is clamped with asupport metal 660 from the bottom side of a cylindrical mandrel 630,while a straight portion 551 of the ribbon plate is retained by anadjustment guide 670 adapted for adjusting a film take-out gap betweenthe straight portion 551 of the ribbon plate and a haze portion (foldedportion) 552, having a port width 553.

Incidentally, with respect to a method for rounding the boat-shapedribbon plate to a cylindrical shape, a variety of methods andapparatuses are made up, for example, there is a ribbon plate formingapparatus as shown in FIG. 24 (refer to JP Patent Kokai Publication No.JP-A-4-102844).

Referring to FIG. 24(A), in this ribbon plate forming apparatus 800, aboat-shaped ribbon plate 750 is placed astride on a die 801 havinghalf-round-opposed recesses which can be moved from side to side, asupport metal 803 cushioned by a spring 802 is arranged in the middle ofthe die 801, and a mandrel 804 which can move to the support metal 803is arranged on top of the boat-shaped ribbon plate 750.

Referring to FIG. 24(B) next, when the mandrel 804 moves to the supportmetal 803 and enters between the recesses of the die 801, the ribbonplate 750 becomes like U-shape.

Referring to FIG. 24(C) further, when the mandrel 804 enters between therecesses of the die 801 completely, the ribbon plate 750 is rounded to acylindrical shape by moving the mandrel 804 to the support metal 803 andwinding up the ribbon plate 750 around the outer surface of the mandrel804.

SUMMARY OF THE DISCLOSURE

In the first aspect, the conventional film cartridge manufacturingapparatus suffers from the following problem. That is, since thevariegated functions exemplified by (1) the rounding of the ribbonplate, (2) cap insertion or (3) cap clinching are congested in theone-capped cartridge producing unit (120 of FIG. 6), among therespective stations arranged around the index unit, the residence timein one station is protracted, thus imposing limitations on thethroughput per unit time. Conversely, there is produced blank time inthe process other than the one-capped cartridge producing unit 120during which no operation is performed, thus lowering the efficiency(see FIG. 6).

On the other hand, the ribbon plate transfer process of the conventionalribbon plate supply unit suffers from the following problems. That is,referring to FIGS. 7 and 8, (1) the tray 204 at the boat-shaped ribbonplate takeout position is at the lowest position of the mechanicalsystem, thus increasing the stroke of the uplifting cylinder of theholding means 221; (2) the bottom surface of the holding means 220 isinclined by being rotated from a horizontal orientation to an anglewhich is in meeting with the angle of the inclined base 231 of thestocker, thus complicating the mechanical structure; (3) if the ribbonplates are not stacked evenly, such as when the number of the ribbonplates is short of a preset number or when a given ribbon plate is of athin thickness due to fluctuations from one product to another, theribbon plate 203, retained solely by the magnet or by the claws in theholding means 221, tends to descend due to the impact at the time oftransportation or tilting, or (4) if a gap is produced between theneighboring ribbon plates 203, the ribbon plates may be tilted and falldown such that the plate surface of the ribbon plate tends to be suckedby the magnet of the holding means 221.

Moreover, referring to FIGS. 9 and 10, the ribbon plate transfer processof the conventional ribbon plate supply unit suffers from the problemthat the arraying of the ribbon plates tends to be disturbed or out oforder in a transition area of the stocker 230 from the inclined base 231towards the outlet 232 of the stocker 230, referred to below as an Rarea, in which the angle of inclination is changed, thus producingribbon plate take-out error or cessation of the entire operation.

According to the inventor's view, the reason for such disturbed arrayingof the ribbon plates is presumably such that, first of all, the linepressure is fractionated when the boat-shaped ribbon plates are thrustfrom a high side by for example a stacker weight at the R area, suchthat the force is not applied uniformly up to the outlet 232, secondly,the friction of the upper end faces of the boat-shaped ribbon plateswith the chute contact surface and that between the lower end faces ofthe boat-shaped ribbon plates with the chute contact surface tend to benonuniform during the time the ribbon plates are moved through the Rarea, and that, third, there is produced a timing differential betweenthe timing of taking out the ribbon plates one-by-one and the timing oftransport (movement) of the ribbon plates by the stacker weight.

In the second aspect, if the port width 553 is adjusted by an adjustmentguide 670, as in the conventional assembly chuck, the magnitude of theport width 553 is varied due to fluctuations in the characteristics ofthe spring plate used in the ribbon plate 550 (springback or SB), thusproducing shape instabilities of the ribbon plates 550 (see FIG. 18).

In addition, if, in the conventional assembly chuck, the movement speedincreases, the ribbon plates cannot be held in stability, so that theabove problem is felt more acutely. Thus, in clinching the cap, the capor the ribbon plate tends to be deformed. Moreover, if the shape of thefilm cartridge deviates from the true circle, localized pressure isapplied to the internal film thus grazing the film as an ultimateproduct. Furthermore, there are occasions where the deviation in theport width or the ends of the haze (folded) or straight portions exceedsthe values prescribed in the standard to cause light to be intruded intothe film cartridge to cause troubles in light shielding properties inthe film.

In the third aspect, it is also a problem in the conventional ribbonplate forming apparatus that the final product of the ribbon plate showsa polygonal shape by the formation of slightly over-bent portion (see753 of FIG. 24(B)) due to the springback effect of the ribbon plate whenthe ribbon plate is tried to round under high speed operating conditions

In the conventional ribbon plate forming apparatus, the roundingoperation of the ribbon plate using the pressure of the resiliencymaterial such as a spring, tends to vibrate severely and become unstablewith discontinuous movement. As a result, the pressure to the ribbonplate is nonuniform and the stability or accuracy of shape of therounded ribbon plate is impaired.

It is further a problem in the conventional ribbon plate formingapparatus that the press of the rounded ribbon plate between the recessof die and the mandrel grazes the surface of the ribbon plate due to thefriction between the surface of recess of die and the outer surface ofthe ribbon plate.

In the first aspect, it is an object of the present invention to providea method and apparatus for manufacturing a film cartridge which lendsitself to high speed operation.

It is an another object in the first aspect of the present invention toprovide a method and apparatus for supplying a plate material having asimplified mechanism.

It is a further object in the first aspect of the present invention toprovide a method and apparatus for supplying a plate material capable ofsupplying boat-shaped ribbon plates in stability.

In the second aspect, it is an object of the present invention toprovide a film cartridge assembling apparatus capable of holding theboat-shaped ribbon plates in stability even under high speed operatingconditions.

It is an another object in the second aspect of the present invention toprovide a film cartridge assembling apparatus capable of assuringstabilized (uniform) film cartridge shape even under high speedoperating conditions.

In the third aspect, it is an object of the present invention to providea film cartridge forming apparatus capable of approximating the roundedshape of the ribbon plate to a perfect circle under high speed operatingconditions.

It is an another object in the third aspect of the present invention toprovide a f film cartridge forming apparatus capable of carrying out astabilized operation under high speed operating conditions.

It is a further object in the third aspect of the present invention toprovide a film cartridge forming apparatus capable of preventing thegrazing on the surface of the ribbon plate.

In an aspect 1 a, the present invention provides a method formanufacturing a film cartridge comprised of a ribbon plate rounded to acylindrical shape so as to leave a gap for taking out a film, and a capclinched to an end of the rounded ribbon plate, by an apparatusincluding a plurality of assembly chucks, each for detachably holdingthe ribbon plate, index unit rotatable about a rotation axis as centerand adapted for holding the assembly chucks at a preset angular intervalabout the rotation axis, and driving unit for intermittently rotatingthe index unit at an angular pitch equal to the preset angular interval,in which the method includes a first step of introducing a ribbon plate,rounded to a cylindrical shape, to an assembly chuck capable ofreceiving the ribbon plate, when the assembly chuck is halted at a haltposition, a second step of inserting the cap to a side end of the ribbonplate, in conjunction with the first step, when the assembly chuck,holding the ribbon plate in the cylindrically rounded state, is haltedat a different halt position, and a third step of clinching the cap tothe ribbon plate, in conjunction with the first step, when the assemblychuck, holding the ribbon plate, having the cap inserted therein, ishalted at a further different halt position.

Preferably, the film cartridge manufacturing method further includes afourth step of rounding the ribbon plate transported as a substantiallyflat plate in conjunction with the first step to a cylindrical shapebefore inserting the rounded ribbon plate into the assembly chuck.

Preferably, the film cartridge manufacturing method further includes afifth step of detecting, in conjunction with the first step, whether ornot the ribbon plate having the cap clinched thereto is acceptable, whenthe assembly chuck, holding the ribbon plate having the cap clinchedthereto, is halted at a further different halt position, a sixth step ofdischarging, in conjunction with the first step, a ribbon plate, foundto be acceptable, based on detected results, when the assembly chuck,holding the detected ribbon plate, is halted at a further different haltposition, and a seventh step of discharging, in conjunction with thefirst step, a ribbon plate not discharged as being acceptable, when theassembly chuck is halted at a further different halt position.

In an aspect 1 b, the present invention provides a plate materialsupplying method including a step of uplifting a tray, loaded with aplurality of substantially flat plates, aligned in upstanding positions,to a preset height, a step of tilting the tray from a horizontal stateto a preset angle, and a step of holding together the preset number ofplates set on the tray maintained in uplifted and tilted state, andtransferring the plates in the tilted state at the preset angle onto aninclined base of a stocker inclined at the same angle as the presetangle.

In an aspect 1 c, the present invention provides a plate materialsupplying method including a step of sliding together the pluralsubstantially flat plates, aligned in upstanding positions on theinclined base, towards a low side, and retaining the plates in thevicinity of a outlet of the stocker, and a step of sucking and takingout the plates in the upstanding positions one by one from the outlet ofthe stocker, by suitably alternately retaining and releasing the plates,and setting the sucked plates from the upstanding positions to thehorizontal positions.

Preferably, the plate material supplying method further includes a stepof holding the plates in the horizontal positions on an upper surface ofa transport table including a magnet and transporting the plates to thenext step.

In an aspect 1 d, the present invention provides an apparatus formanufacturing a film cartridge including a plurality of assembly chuckseach for detachably holding a ribbon plate, index unit adapted for beingrotated about a rotation axis and for holding the assembly chucks at apreset angular interval about the rotation axis, driving unit forintermittently rotating the index unit at an angular pitch equal to thepreset angular interval, ribbon plate inserting unit for inserting aribbon plate, rounded to a cylindrical shape, into an assembly chuck,capable of receiving the ribbon plate, when the assembly chuck is haltedat a halt position, capping unit for inserting, in conjunction with theoperation of the ribbon plate inserting unit, a cap into a side end ofthe ribbon plate, when the assembly chuck, holding the ribbon plate inthe cylindrically rounded state, is halted at a different halt position,and clinching unit for clinching and affixing the cap to the ribbonplate, in conjunction with the operation of the ribbon plate insertingunit, when the assembly chuck, holding the ribbon plate, having the capinserted therein, is halted at a further different halt position.

Preferably, the film cartridge manufacturing apparatus of the presentinvention further includes forming unit for rounding the ribbon plate asa substantially flat plate, to a cylindrical shape, in conjunction withthe operation of the ribbon plate inserting unit, before delivering therounded ribbon plate to the ribbon plate inserting unit.

Preferably, the film cartridge manufacturing apparatus further includesinspecting unit for detecting, in conjunction with the operation of theribbon plate inserting unit, whether or not the ribbon plate having thecap clinched thereto is acceptable, when the assembly chuck, holding theribbon plate having the cap clinched thereto, is halted at a furtherdifferent halt position, acceptable ribbon plate discharging unit fordischarging, in conjunction with the operation of the ribbon plateinserting unit, a ribbon plate, found to be acceptable, based ondetected results, when the assembly chuck, holding the detected ribbonplate, is halted at a further different halt position, and remnantdischarging unit for discharging, in conjunction with the operation ofthe ribbon plate inserting unit, a ribbon plate not discharged as beingacceptable, when the assembly chuck is halted at a further differenthalt position.

In an aspect 1 e, the present invention provides an apparatus forsupplying plate materials including a stocker including an inclinedbase, tilted to an angle equal to the tilt angle of the tray, forholding together a plurality of substantially flat plates, aligned inupstanding positions on the inclined base, and a outlet for taking outthe plates thus held from a low side of the inclined base, a slidemechanism for sliding together the plural substantially flat plates,aligned in upstanding positions on the inclined base, towards a lowside, retention unit for retaining the plates, slid thereto, in alignedupstanding positions, and suitably releasing the retention to enable theplates to be taken out one by one, and a suction transport mechanismincluding suction unit for sucking, one by one, the plates, taken outvia a outlet of the stocker, and transporting unit for transporting theplates, sucked by the suction unit, from the upstanding position to thehorizontal position.

Preferably, the plate material supplying apparatus of the presentinvention includes a transport table having a magnet internally mountedthereto for holding the ribbon plates, sucked and transported thereto inthe horizontal positions, and transporting unit for transporting theribbon plates held on an upper surface thereof to the next process stepunit.

In an aspect 1 f, the plate material supplying apparatus of the presentinvention further includes a lifter for uplifting the tray, loaded withthe plural substantially flat plates, in the aligned upstandingpositions, to a preset height, a tilt mechanism for tilting the trayfrom the horizontal position to a tilt angle corresponding to the tiltangle of the inclined base, holding means including gripper having abottom surface inclined to the same angle as the tilt angle of theinclined base and an internally mounted magnet, the gripper gripping theplate on the bottom surface, the holding means holding together a presetnumber of said plates set on the inclined tray by suction by the magnetonto the bottom surface and gripping by the gripper, and a transportmechanism connected to the holding means for transporting the platesheld by the holding means to a preset position as the angle of thebottom surface of the holding means is maintained.

In an aspect 2 a, the present invention provides a film cartridgeassembling apparatus for assembling a film cartridge, made up by aribbon plate holding a photographic roll film therein and a cap, inwhich the apparatus includes one or more assembly chuck(s) eachincluding two form elements formed by combining partial cylindricalinner surfaces thereof together, the circumference of a resultingcylinder being partially cut to form an opening, one of the formelements including a member having a flat surface extending from an endof the cylindrically-shaped inner surface. The member is adjustablymounted to the one of the form elements. The assembly chuck is able toassume a closed state in which the two inner surfaces of the two formelements are matched to each other to form a cylindrical inner surfaceand an opened state in which ends of the two form elements substantiallyparallel to the center axis of the cylindrical inner surface are spacedapart from each other.

Preferably, the other of the form elements includes an edge memberhaving an edge end facing the one of the form elements. The edge memberis adjustably combined with the end of the cylindrical inner surface ofthe other form element.

In an aspect 2 b, the present invention provides a film cartridgeassembling apparatus for assembling a film cartridge made up by a ribbonplate, holding a photographic roll film therein, and a cap, in which theapparatus includes one or more assembly chuck(s) each including two formelements formed by combining partial cylindrical inner surfaces thereoftogether, the circumference of a resulting cylinder being partially cutto form an opening. One of the form elements includes a member having aflat surface extending from an end of the cylindrically-shaped innersurface, and which is adjustably mounted to the one form element, whilethe other of the form elements includes an edge member having an edgeend facing the one form element, and which is adjustably combined withthe end of the cylindrical inner surface of the other form element. Thetwo form elements are able to assume a closed state in which the twoinner surfaces of the two form elements are matched to each other toform a cylindrical inner surface and an opened state in which ends ofthe two form elements substantially parallel to the center axis of thecylindrical inner surface are spaced apart from each other. The anglebetween a line interconnecting the center axis and the edge end and aline interconnecting a boundary line between the cylindrical innersurface and the flat surface and the center axis in the transversecross-section in the closed state is not less than 25° and not largerthan 50°.

In this film cartridge assembling apparatus, the angle between a lineinterconnecting the center axis and the edge end and a lineinterconnecting a boundary line between the cylindrical inner surfaceand the flat surface and the center axis in the transverse cross-sectionin the closed state is not less than 30° and not larger than 40°.

Preferably, the film cartridge assembling apparatus further includes amagnet internally mounted in the vicinity of a distal end face of themandrel.

Preferably, the film cartridge assembling apparatus further includes adischarging mechanism for discharging a ribbon plate or a one-cappedcartridge, held by the mandrel, and which is made up by a ribbon plateand a cap clinched to a single side end of the ribbon plate, when theform elements are opened apart from each other,.

In the film cartridge assembling apparatus of the present invention, thedischarging mechanism preferably includes one or more guide groovesformed in the horizontal direction in a cylindrical surface of themandrel, and a component of the discharging mechanism having a pinslidable in the guide groove, the component of the discharging mechanismthrusting an end of the ribbon plate for discharging the ribbon plate bythe distal end of the mandrel.

Preferably, the film cartridge assembling apparatus includes index unitrotatable about a rotation axis as center and adapted for holding theassembly chucks at an equi-angular interval about the rotation axis, anddriving unit for intermittently rotating the index unit at an angularpitch equal to the angular interval.

In the film cartridge assembling apparatus of the present invention, theindex unit is preferably arranged with its rotation axis mounted atright angles to a substantially horizontal surface and is held such thatthe long axis of the assembly chuck is substantially horizontal and isoriented towards the rotation axis.

In an aspect 3 a, the present invention provides a film cartridgeforming apparatus for rounding a ribbon plate of a film cartridge,having accommodated therein a photographic roll film, comprising amandrel having a cylindrically-shaped surface section, a roundingmechanism having a pair of first rollers mounted for rotation forrounding the ribbon plate to a cylindrical shape by said paired firstrollers pressing said ribbon plate against said mandrel along saidcylindrically-shaped surface section of said mandrel, as said ribbonplate is moved, and a guide mechanism for guiding the operation of saidrounding mechanism so that said paired first rollers are moved alongsaid cylindrically-shaped surface section of said mandrel.

In an aspect 3 b, the present invention provides a film cartridgeforming apparatus for rounding a ribbon plate of a film cartridge,having accommodated therein a photographic roll film, comprising amandrel having a cylindrically-shaped surface section, a support metalfor clamping the ribbon plate in cooperation with the mandrel as saidribbon plate is compressed against the cylindrically-shaped surfacesection of said mandrel, a rounding mechanism having a pair of firstrollers mounted for rotation for rounding the ribbon plate to acylindrical shape by said paired first rollers pressing both lateralsites of a clamp section for said ribbon plate against said mandrelalong both outer sides of said support metal or the cylindrically-shapedsurface section of said mandrel, as said ribbon plate is moved, and aguide mechanism for guiding the operation of said rounding mechanism sothat said paired first rollers are moved along said cylindrically-shapedsurface section of said mandrel.

In the film cartridge forming apparatus of the present invention, therounding mechanism preferably includes a pair of second rollers mountedfor rotation, said paired second rollers thrusting thecylindrically-shaped surface section of said ribbon plate when saidribbon plate is rounded by said paired first rollers.

In the film cartridge forming apparatus of the present invention, theguide mechanism preferably presses the ribbon plate against the pairedfirst rollers and guides the operation of said rounding mechanism sothat a portion of said ribbon plate compresses against thecylindrically-shaped surface section of said mandrel.

In the film cartridge forming apparatus of the present invention, theguide mechanism preferably includes a pair of cam followers operativelyassociated with said paired first rollers and a guide member having agroove for guiding said paired cam followers so that said paired firstrollers are moved along the cylindrically-shaped surface section of saidmandrel.

In the film cartridge forming apparatus of the present invention, thereare preferably provided a retention pawl for retaining a haze part and astraight part of the rounded ribbon plate and a feed claw for feedingout the ribbon plate as said haze part and a straight part of the ribbonplate are retained.

In the film cartridge forming apparatus of the present invention, themandrel preferably includes a passage section for transporting theribbon plate in a portion thereof extending from the clamp section withsaid support metal, and a magnet mounted in the vicinity of the bottomof a recess formed in the bottom of said passage section as said magnetis separated from the bottom of said surface section.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram schematically showing the structure of a filmcartridge manufacturing apparatus of a first embodiment of the presentinvention.

FIG. 2 is a side view schematically showing the structure of a ribbonplate transfer process sub-unit of a ribbon plate supply unit of a firstembodiment of the present invention.

FIG. 3 is a side view schematically showing the structure of a ribbonplate supply process unit of the ribbon plate supply unit of the firstembodiment of the present invention.

FIGS. 4A to 4D are cross-sectional views schematically showing theoperation of a capping unit of the first embodiment of the presentinvention.

FIG. 5 is an exploded perspective view schematically showing thestructure of the film cartridge.

FIG. 6 is a block diagram schematically showing the structure of aconventional typical apparatus for producing a film cartridge.

FIG. 7 is a side view schematically showing the structure of a ribbonplate transfer process sub-unit of a conventional typical ribbon platesupply unit

FIG. 8 is a partial plan view schematically showing the structure of theribbon plate transfer process sub-unit of the conventional typicalribbon plate supply unit.

FIG. 9 is a first side view schematically showing the structure of aribbon plate supply process unit of the conventional typical ribbonplate supply unit.

FIG. 10 is a second side view schematically showing the structure of aribbon plate supply process unit of the conventional typical ribbonplate supply unit.

FIG. 11 is a plan view schematically showing the structure of a filmcartridge assembling apparatus of a second embodiment of the presentinvention.

FIG. 12 is a cross-sectional view taken along line X-X′ of FIG. 11schematically illustrating the structure of an assembly chuck in a filmcartridge assembling apparatus of the second embodiment of the presentinvention.

FIGS. 13A to 13C are front views, looking along the direction of arrow Ain FIG. 11, schematically illustrating the operation of an assemblychuck in the film cartridge assembling apparatus of the secondembodiment of the present invention.

FIG. 14 is a cross-sectional view, taken along line Y-Y′ of FIG. 12, forschematically showing the assembly chuck and the manner of inserting acap onto a mandrel in the film cartridge assembling apparatus of thesecond embodiment of the present invention.

FIG. 15 is a perspective view schematically showing the structure of themandrel and an ejection mechanism member in the film cartridgeassembling apparatus of the second embodiment of the present invention.

FIG. 16 is a block diagram schematically showing the structure of a filmcartridge assembling apparatus of the second embodiment of the presentinvention.

FIG. 17 is a cross-sectional view, taken along line Y-Y′ of FIG. 12,schematically showing the assembly chuck and the manner of clinching acap of a mandrel in the film cartridge assembling apparatus of thesecond embodiment of the present invention.

FIG. 18 is a front view schematically showing the structure of a typicalconventional assembly chuck.

FIG. 19 is a partial side view schematically showing the structure of afilm cartridge forming apparatus of a third embodiment of the presentinvention.

FIG. 20 is a partial front view schematically showing the structure ofthe film cartridge forming apparatus of the third embodiment of thepresent invention.

FIGS. 21(A) to 21(C) are partial side views schematically showing thestates of rounding (on the way of ascending) of the film cartridgeforming apparatus of the third embodiment of the present invention.

FIG. 22 is a partial side view schematically showing the state ofrounding (end of ascending) of the film cartridge forming apparatus ofthe third embodiment of the present invention.

FIG. 23 is a partial side view schematically showing the state ofretention of the film cartridge forming apparatus of the thirdembodiment of the present invention.

FIGS. 24(A) to 24(C) are partial side views schematically showing astructure of conventional film cartridge forming apparatus.

PREFERRED EMBODIMENTS OF THE INVENTION

An apparatus for manufacturing a film cartridge, made up by a ribbonplate holding a photographic roll film therein and a cap, includes aplurality of assembly chucks (10 of FIG. 1) each for detachably holdinga ribbon plate, index unit (9 of FIG. 1) adapted for being rotated abouta rotation axis and for holding the assembly chucks at a preset angularinterval about the rotation axis, driving unit (16 of FIG. 1) forintermittently rotating the index unit at an angular pitch equal to thepreset angular interval, ribbon plate inserting unit (15 of FIG. 1) forinserting a ribbon plate, rounded to a cylindrical shape, into anassembly chuck, capable of receiving the ribbon plate, when the assemblychuck is halted at a halt position, capping unit (4 of FIG. 1) forinserting, in conjunction with the operation of the ribbon plateinserting unit, a cap into a side end of the ribbon plate, when theassembly chuck, holding the ribbon plate in the cylindrically roundedstate, is halted at a different halt position and clinching unit (5 ofFIG. 1) for clinching and affixing the cap to the ribbon plate, inconjunction with the operation of the ribbon plate inserting unit, whenthe assembly chuck, holding the ribbon plate, having the cap insertedtherein, is halted at a further different halt position, whereby theprocess steps of ribbon plate rounding, cap insertion and cap clinchingmay be carried out simultaneously to shorten the residence time in therespective process steps.

An apparatus for supplying plate materials (11 of FIG. 2) includes alifter (30, 31, 32 of FIG. 2) for uplifting a tray (13 of FIG. 2),loaded with a plurality of plate materials, aligned in upstandingpositions, to a preset height, a tilting mechanism (40 of FIG. 2) fortilting the tray from the horizontal state to a preset angle, holdingmeans (51 of FIG. 2) including gripper (52 of FIG. 2) having a bottomsurface (57 of FIG. 2) inclined to the same angle as the tilt angle ofthe tray and an internally mounted magnet (53 of FIG. 2) for grippingthe ribbon plate on the bottom surface, the holding means holdingtogether a preset number of ribbon plates set on the tray by suction bythe magnet onto the bottom surface and gripping by the gripper, and atransport mechanism (54, 55, 56 of FIG. 2) connected to the holdingmeans for transporting the ribbon plates held by the holding means to apreset position as the angle of the bottom surface of the holding meansis maintained, whereby the ribbon plates can be transported in an evenlyaligned state, so that there is scarcely any risk of dropping the platesfrom the holding means.

An apparatus for supplying plate materials (12 of FIG. 3) includes astocker (60 of FIG. 3) including an inclined base (61 of FIG. 3), tiltedat a preset angle, for holding a plurality of plates (14 of FIG. 3) inaligned upstanding positions on the inclined base, and a outlet (62 ofFIG. 3) for taking out the plate materials thus held from the low sideof the inclined base, a slide mechanism (66 of FIG. 3) for slidingtogether the plural plate members in aligned upstanding positions on theinclined base towards the low side, retention means (63 of FIG. 3) forretaining the plate materials, slid thereto, in the aligned upstandingpositions, and for suitably releasing the retention to enable the platematerials to be taken out one by one, and a suction transport mechanism(70 of FIG. 3) including suction unit (71 of FIG. 3) for sucking theplate materials, taken out one by one from the outlet of the stocker,and transport mechanism (72 of FIG. 3) for transporting the ribbonplates sucked by the suction unit from the upstanding position to thehorizontal position.

A film cartridge assembling apparatus for assembling a film cartridge,made up by a ribbon plate (550 of FIG. 12) holding a photographic rollfilm therein and a cap, includes one or more assembly chuck(s) (520 ofFIG. 12) each including two form elements (521, 522 of FIG. 12) formedby combining partial cylindrical inner surfaces (521 a, 522 a of FIG.12) thereof together, the circumference of a resulting cylinder beingpartially cut to form an opening, one of the form elements (522 of FIG.2) including a member (522 of FIG. 12) having a flat surface extendingfrom an end of the cylindrically-shaped inner surface (522 a of FIG.12), the member being adjustably mounted to the one of the formelements, the assembly chuck being able to assume a closed state (FIG.13(A)) in which the two inner surfaces of the two form elements arematched to each other to form a cylindrical inner surface and an openedstate (FIG. 13(C)) in which ends of the two form elements substantiallyparallel to the center axis of the cylindrical inner surface are spacedapart from each other. Thus, the cylindrical inner surface of the ribbonplate may be retained by the cylindrical surface of the form element,while the straight portion of the ribbon plate may be retained by the(fixed) member combined with one of the form elements, so that theentire outer peripheral surface of the ribbon plate, excluding the filmtakeout port and the near-by area, may be retained, whereby theribbonplate maybe retained in stability even under high speed operationswithout fluctuations in the port width (width between the haze part andthe end of the straight portion) due to springback.

A film cartridge assembling apparatus for assembling a film cartridgemade up by a ribbon plate (550 of FIG. 12) holding a photographic rollfilm therein and a cap, includes one or more assembly chuck(s) (520 ofFIG. 12) each including two form elements (521, 522 of FIG. 12) formedby combining partial cylindrical inner surfaces (521 a, 522 a of FIG.12) thereof together, the circumference of a resulting cylinder beingpartially cut to form an opening, one of the form elements (522 of FIG.12) including a member (522 b of FIG. 12) having a flat surfaceextending from an end of the cylindrically-shaped inner surface (522 aof FIG. 12), the member being adjustably mounted to the one formelement, the other of the form elements (521 of FIG. 12) including anedge member (521 b of FIG. 12) having an edge end facing the one formelement (522 of FIG. 12), the edge member being adjustably combined withthe end of the cylindrical inner surface of the other form element, thetwo form elements being able to assume a closed state (FIG. 13(A)) inwhich the two inner surfaces of the two form elements are matched toeach other to form a cylindrical inner surface and an opened state (FIG.13(C)) in which ends of the two form elements substantially parallel tothe center axis of the cylindrical inner surface are spaced apart fromeach other. The angle (θ of FIG. 12) between a line (542 of FIG. 12)interconnecting the center axis (540 of FIG. 12) and the edge end and aline (541 of FIG. 12) interconnecting a boundary line between thecylindrical inner surface and the flat surface and the center axis inthe transverse cross-section in the closed state is not less than 25°and not larger than 50°. The cylindrically-shaped surface of the ribbonplate may be retained by the cylindrically-shaped surfaces of the formelements, while the haze part of the ribbon plate is retained by theedge member combined (secured) to the other form element and thestraight portion of the ribbon plate is retained by the fixed chuckmember combined with the one form element, so that, even under a highspeed operation, the ribbon plate may be held in a state of producing afilm cartridge in which the equilibrium may be maintained between thefilm pull-out torque and the light shielding properties, that is in astate of holding the ribbon plate by the entire circumference of theribbon plate minus an arcuate area corresponding to the angle θ. Itshould be noted that, if the angle θ is too small, the film pull-outtorque is increased, thus possibly causing malfunctions on the sidecamera. If conversely the angle θ is too large, light tends to beintruded via a port thus possibly deteriorating the light shieldingproperties. It is therefore desirable that the angle θ is larger than25° and smaller than 50°.

A film cartridge forming apparatus for rounding a ribbon plate of a filmcartridge, having accommodated therein a photographic roll filmcomprises a mandrel (701 of FIG. 19) having a cylindrically-shapedsurface section, a rounding mechanism (704, 709, 710, 711, 721, 722 ofFIG. 19) having a pair of first rollers (703 of FIG. 19) mounted forrotation for rounding the ribbon plate to a cylindrical shape by saidpaired first rollers pressing said ribbon plate against said mandrelalong said cylindrically-shaped surface section of said mandrel, as saidribbon plate is moved, and a guide mechanism (704, 707, 716, 717 of FIG.19) for guiding the operation of said rounding mechanism so that saidpaired first rollers are moved along said cylindrically-shaped surfacesection of said mandrel, resulting in that the track of the firstrollers can be regulated by the guide mechanism even under a high speedoperation.

A first embodiment of the present invention is now explained withreference to the drawings. FIG. 1 is a block diagram schematicallyshowing a structure of a film cartridge manufacturing apparatus of thefirst embodiment of the present invention.

Referring to FIG. 1, this film cartridge manufacturing apparatus 1 usesa rotary index with six stations, and includes a ribbon plate supplyunit 2, a rounding unit 3, a capping unit 4, a clinching unit 5, aninspecting unit 6, an acceptable product discharging unit 7, a remnantdischarging unit 8, an index unit 9 and an assembly chuck 10.

The ribbon plate supply unit 2 is responsible for transferring aboat-shaped ribbon plate, loaded on a tray, and for supplying thetransferred boat-shaped ribbon plate to a cylindrical shape (see FIG.1). The detailed structure of this ribbon plate supply unit will beexplained later on.

The rounding unit 3 is responsible for rounding the boat-shaped ribbonplate, supplied from the ribbon plate supply unit 2, to a cylindricalshape (see FIG. 1). For rounding the boat-shaped ribbon plate to acylindrical shape, reference is had, as an example, to the Publicationof the JP Patent Kokai JP-A-63-199035. A ribbon plate insertion unit 15is arranged between the rounding unit 3 and the assembly chuck 10 of theindex unit 9 lying in its vicinity. When the assembly chuck 10 is haltedat a halt position, the ribbon plate insertion unit 15 introduces theribbon plate, rounded to a cylindrical shape, into the assembly chuck10, lying in the proximate position, in conjunction with the operationof the rounding unit 3, so that the opened portion of the ribbon plate,rounded to the cylindrical shape, will be located in the open portion ofthe assembly chuck 10.

When the index unit 9 is rotated one pitch and the assembly chuck 10holding the rounded ribbon plate is held at another halt position, thecapping unit 4 introduces the cap to one side end (outer peripheralside) of the ribbon plate, in conjunction with the operation of therounding unit 3 (ribbon plate insertion unit 15) (see FIG. 1). Thedetailed structure of the capping unit 4 will be explained subsequently.

When the index unit 9 is rotated one pitch and the assembly chuckholding the ribbon plate, having the cap mounted thereto, is halted atanother halt position, the clinching unit 5 clinches and secures the capto the ribbon plate, in conjunction with the operation of the roundingunit 3 (ribbon plate insertion unit 15) (see FIG. 1). This clinchingoperation completes the one-capped cartridge as it is so-called. Thisclinching may be by any suitable conventional or non-conventionalmethod. As for a typical conventional clinching method, reference is hadto the JP Patent Kokai JP-A-63-199035.

When the index unit 9 has rotated one pitch and the assembly chuckholding the film cartridge, opened on its one side end, in another haltposition, the inspecting unit 6 detects, in conjunction with theoperation of the rounding unit 3 (ribbon plate insertion unit 15)whether or not the one-capped cartridge is acceptable (see FIG. 1). Thedetection method may be any suitable conventional or non-conventionaldetection methods provided that the methods used allow for detectionwhether or not the ribbon plate is acceptable or unacceptable, such as amethod employing mechanical thrusting for detection, illuminatinginfrared rays to the one-capped cartridge to detect the reflected light,or processing and detecting the picture information as picked up by acamera.

When the index unit 9 is rotated one pitch and the assembly chuckholding the one-capped cartridge as detected is halted at another haltposition, the acceptable product discharging unit 7 ejects theacceptable one-capped cartridge, based on the results as detected by theinspecting unit 6, in conjunction with the operation of the roundingunit 3 (ribbon plate insertion unit 15) (see FIG. 1). The dischargingmay be by any conventional or non-conventional detection methods.

When the index unit 9 is rotated one pitch and the assembly chuck 10 ishalted at another halt position, the remnant discharging unit 8 ejectsthe one-capped cartridge, which has not been ejected as an acceptableproduct, or a remnant (for example, only a cap or a ribbon plate), inconjunction with the operation of the rounding unit 3 (ribbon plateinsertion unit 15) (see FIG. 1). The discharging may be by anyconventional or non-conventional discharging methods.

The index unit 9 may be rotated about a rotation axis as center to holdthe six assembly chucks 10 at an equi-angular interval about therotation axis(see FIG. 1). The index unit 9 is intermittently rotated bythe driving unit 16 at an angular pitch equal to the angular interval.As for a conventional structure of the index unit 9, reference may behad to the Publication of the JP Patent Kokai JP-A-1-287670.

The assembly chuck 10 is a mechanical component for detachably grippingthe ribbon plate. Six such assembly chucks 10 are mounted atequi-angular intervals about the rotation axis of the index unit 9 inassociation with the six stations (see FIG. 1). The assembly chuck 10 iscapable of holding the ribbon plate in a cylindrically roundedcondition. The assembly chuck 10 may be of any suitable conventional ornon-conventional structure. As for a typical conventional assembly chuck10, reference may be had to the Publication of the JP Patent KokaiJP-A-1-287670.

The operation of the film cartridge manufacturing apparatus of the firstembodiment is now explained.

Referring to FIG. 1 first, the boat-shaped ribbon plate is supplied fromthe ribbon plate supply unit 2 to the rounding unit 3 where theboat-shaped ribbon plate supplied is rounded to a cylindrical shape.

The ribbon plate in the rounded state is transported to the near-byassembly chuck 10, in the halted state. In this assembly chuck 10, wherethe ribbon plate may be accepted, the ribbon plate is held in thecylindrically rounded condition (see FIG. 1).

When the index unit 9 is further rotated one pitch and halted at thenext halt position, a cap is introduced at the capping unit 4 into oneside end (outer peripheral side) of the ribbon plate, halted asdescribed above (see FIG. 1).

When the index unit 9 is further rotated one pitch and halted at anotherhalt position, the cap, already mounted to the ribbon plate, is clinchedto the ribbon plate in the clinching unit 5 to form the one-cappedcartridge (see FIG. 1).

When the index unit 9 is further rotated one pitch and halted at anotherhalt position, the inspecting unit 6 monitors the state of engagementbetween the ribbon plate and the cap of the so formed one-cappedcartridge to detect whether or not the one-capped cartridge isacceptable (see FIG. 1).

When the index unit 9 is further rotated one pitch and halted at anotherhalt position, the acceptable product discharging unit 7 ejects theacceptable one-capped cartridge, based on the results detected by theinspecting unit 6 (see FIG. 1). If the one-capped cartridge has beenfound to be unacceptable, this unacceptable one-capped cartridge is notdischarged.

When the index unit 9 is further rotated one pitch and halted at anotherhalt position, and there exists the unacceptable one-capped cartridge,the remnant discharging unit 8 ejects the one-capped cartridge notdischarged by the acceptable product discharging unit 7 or remnants(such as isolated caps or ribbon plates, left due to some unusualsituation) are ejected (see FIG. 1).

When the index unit 9 is further rotated one pitch and halted at anotherhalt position, the ribbon plate, rounded by the rounding unit 3, isintroduced into the empty assembly chuck 10. The above-describedsequence of operations then is repeated (see FIG. 1). The operations inthe respective process step units are carried out in conjunction withone another such that a one-capped cartridge is completed for eachone-pitch rotation of the index unit 9.

By the above structure, the rounding of the ribbon plate, cap insertionand cap clinching may be carried out in the film cartridge manufacturingapparatus simultaneously, thereby enabling a high speed operation.Moreover, since the process step units of ribbon plate rounding, capinsertion and cap clinching are scattered, the mechanical structure issimplified, thus assuring facilitated maintenance.

Referring to the drawings, the ribbon plate supply unit 2 of FIG. 1 isnow explained. FIG. 2 is a side view schematically showing the structureof the ribbon plate transfer process of the ribbon plate supply unit ofthe first embodiment of the present invention. FIG. 3 is a side viewschematically showing the structure of the ribbon plate supply processstep unit of the ribbon plate supply unit of the first embodiment of thepresent invention. The ribbon plate supply process step unit may bedivided into a ribbon plate transfer process for transferring a ribbonplate from a tray loaded with plural ribbon plates to a stocker, and aribbon plate supply process unit for supplying ribbon plated accumulatedin the stocker to the index unit.

Referring to FIG. 2, the ribbon plate transfer process 11 of the ribbonplate supply unit includes a lifter 30, a tilt mechanism 40, a transfermechanism 50 and a stocker 60.

The lifter 30 includes a holding device 31 and a lifter 32 (see FIG. 2).The holding device 31 holds one of plural trays 13 stacked on a traystorage site. The lifter 32 is a means for uplifting the tray 13 held bythe holding device 31 to a preset height or lowering the so upliftedtray. The tray 13 is loaded with plural boat-shaped ribbon platesaligned in an upstanding position.

The tilt mechanism 40 is a mechanism for tilting the tray 13, held bythe holding means 13 of the lifter, from a horizontal plane to apredetermined angle (see FIG. 2).

The transfer mechanism 50 includes a gripper 51, a claw 52, a magnet 53,a cylinder 54, a sliding unit 55, a rail 56 and a reciprocatingmechanism 59 (see FIG. 2).

The gripper 51 grips together a preset number of boat-shaped ribbonplates 14 from the tray 13 using the claw 52 (see FIG. 2). The tray 13is kept in its height and inclination by the lifter 30 and the tiltmechanism 40. An abutment surface 57 of the gripper 51 against the endof the boat-shaped ribbon plate 14 is inclined in meeting with the tiltangle of the tray 13. In the transfer mechanism 50, no mechanism forchanging the tilt angle of the gripper 51 is used.

The claw 52 is used for gripping both outer surfaces of the platesurface of the boat-shaped ribbon plate 14, aligned in the upstandingposition in readiness for gripping. The claw is arranged on thelongitudinal side edge of the abutment surface 57 of the gripper 51 (seeFIG. 2).

The magnet 53 is used for sucking the end face of the boat-shaped ribbonplate 14 to the abutment surface 57 of the gripper 51, and is mountedwithin the gripper 51 in the vicinity of the abutment surface 57 (seeFIG. 2).

The cylinder 54 is lifter for uplifting the gripper 51 to a presetheight or lowering the uplifted gripper 51 (see FIG. 2).

The sliding unit 55 is means for sliding the cylinder 54 on the rail 56linearly along the horizontal direction (see FIG. 2).

The rail 56 is a rail on which slides the sliding unit 55 and isconnected to a column 58 so as to be extended to above the tray 13 andabove the stocker 60 (see FIG. 2).

The reciprocating mechanism 59 is a cylinder for moving the gripper 51towards the boat-shaped ribbon plate 14 set on the tray 13 (see FIG. 2).

The stocker 60 operates for supplying the accumulated boat-shaped ribbonplates 14 one-by-one and includes a tilted base 61 which is tilted to apreset angle which is the same as the tilt angle of the abutment surface57 of the transfer mechanism 50 (see FIG. 2).

The operation of the ribbon plate transfer process 11 is now explained.

First, the tray 13, loaded with the plural boat-shaped ribbon plates 14,aligned in the upstanding positions, are uplifted to a preset height,using the lifter 30 (see FIG. 2)

Then, as the tray 13 is maintained at a constant height, the tray 3 isinclined to the same angle as the tilt angle of the abutment surface 57of the transfer mechanism 50 (see FIG. 2). At this time, the boat-shapedribbon plates 14 are offset towards one side. Thus, the gap between theneighboring ribbon plates is reduced to zero, with the ribbon platesbeing in a congested condition. Thus, the boat-shaped ribbon plates 14are together subjected to the magnetic force of the magnet 53, thusassuring stable retention.

The gripper 51 of the transfer mechanism 50 is lowered onto the tray 13and intruded into the boat-shaped ribbon plates 14 by the reciprocatingmechanism 59 (see FIG. 2). The preset number of boat-shaped ribbonplates 14 are held together by the gripper 51 in the aligned upstandingposition. The gripper 51 is uplifted, as it holds the boat-shaped ribbonplates 14, then is moved horizontally, and caused to descend at aposition overlying the stock portion 60. The gripper 51 is then advancedtowards the base surface to transfer the boat-shaped ribbon plates 14onto an inclined base 61 of the stocker 60. If the boat-shaped ribbonplates 14 are offset to one side to produce a gap, the gripper 51 is inthe inclined state at all times, so that the ribbon plates are held asthey are inclined in an opposite direction to the direction in which theribbon plates fall flat on the magnet 53, under the effect of gravity.Thus, the ribbon plates are not susceptive to fall down. Moreover, theclaws 52 on both sides of the gripper 51 are pressured inwards, so thatthe ribbon plates may be retained in stability.

Thus, a set of the ribbon plates are transferred to the stocker 60 aretransferred in the aligned upstanding position (see FIG. 2).

Referring to FIG. 3, the ribbon plate supply step unit 12 of the ribbonplate supply unit includes a stocker 60, a suction transport mechanism70 and a receiving block 82

The stocker 60 is the same as the stocker 60 of the ribbon platetransfer process 11 of the ribbon plate supply unit of FIG. 2, andincludes the inclined base 61, a outlet 62, a shutter 63, a retentionplate 64, a magnet 65 and a stacker weight 66 (see FIG. 3). Meanwhile,in FIG. 3, the stocker 60 is shown in a longitudinal cross-section.

The inclined base 61 is a base operating as a storage site for pluralboat-shaped ribbon plates 14, aligned in an upstanding position. Theinclined base 61 is inclined to a preset angle which is the same as theangle of inclination of the abutment surface (see 57 of FIG. 2) of thetransfer mechanism. The base surface is flat and, on the base member,the boat-shaped ribbon plates 14 are slid in the upstanding positionsunder the pressuring by the stacker weight (see FIG. 3).

The outlet 62 is an opening through which the boat-shaped ribbon plates14 accommodated are taken out one-by-one from a lower side of theinclined base (see FIG. 3).

The shutter 63 is retention means for taking out the boat-shaped ribbonplates 14 one-by-one from the outlet 62, and is arranged in the vicinityof the outlet 62 so as to be opened/closed by cam driving (see FIG. 3).

The retention plate 64 is arranged at an upper part of the end of theboat-shaped ribbon plate 14 in order to put the height of theboat-shaped ribbon plates 14 in order(see FIG. 3). One such retentionplate 64 is arranged half-way on the stocker 60 and another is arrangedin the vicinity of the outlet 62. The intermediate retention plate 64 ismoved in the up-and-down direction above the ends of the boat-shapedribbon plates 14, while the retention plate 64 arranged in the in thevicinity of the outlet 62 is moved by cam driving in the up-and-downdirection above the ends of the boat-shaped ribbon plates 14.

The magnet 65 is arranged inwardly of the retention plate 64 in thevicinity of the outlet 62 to prevent falldown of the ribbon platesduring transport thereof (see FIG. 3).

The stacker weight 66 pressures the trailing end of the boat-shapedribbon plates 14 aligned in the upstanding positions (high side) towardsthe outlet 62 (low side) of the boat-shaped ribbon plates 14 (low side).When the boat-shaped ribbon plates 14 are transferred from the tray (13of FIG. 2), the stacker weight is moved by the cylinder towards the highside (see FIG. 3).

The suction transport mechanism 70 includes a suction unit 71 and arotating mechanism 72 (see FIG. 3). The suction unit 71 is a means forsucking or desorbing the boat-shaped ribbon plates 14, taken out fromthe outlet 62 of the stocker, one-by-one by air adjustment. A collarformed of resin is mounted to the suction transport mechanism forinhibiting the pat from being deformed during suction. The rotatingmechanism 72 is a means for rotating the suction unit 71, mounted to thearm 73, for transferring the boat-shaped ribbon plates 14 from theupstanding position to the horizontal position.

The receiving block 80 includes a base 81, a magnet 82 and a slidingmechanism 83 (see FIG. 3). The base portion 81 is a support on which toset the boat-shaped ribbon plate, transported by a suction transportingmechanism 70, in the horizontal position. The magnet 82 is mountedinwardly of the base 81 and is used for holding the boat-shaped ribbonplate 14, set on the base 81, in a prescribed position. The slidingmeans is a means for transporting the boat-shaped ribbon plate 14,placed thereon, to a rounding unit (3 of FIG. 1).

The operation of the ribbon plate supply step unit 12 of the ribbonplate supply unit is now explained.

The set of the boat-shaped ribbon plates 14, transferred on the stocker60, is slid together by the stacker weight 66 as a group towards the lowside, as the ribbon plates are aligned on the inclined base 61 in theupstanding positions (see FIG. 3). The ribbon plates 14 are retained bythe shutter 63 and the ends thereof are aligned by the retention plate64. This removes gaps or disorders in the boat-shaped ribbon plates 14so that the hip-shaped ribbon plates 14 are positioned to facilitatetakeout thereof one-by-one. The impact from the stacker weight 66 isabsorbed by alternate operations of the intermediate retention plate 64and the retention plate 64 in the takeout unit.

The boat-shaped ribbon plates 14, accumulated in the stocker 60, aresucked by a suction unit 71 of the suction transport mechanism 70, inthe upstanding positions, and are taken out one-by-one from the outlet62, by the operation of the retention plate 64 and by theopening/closure of the shutter 63, so as to transfer from the upstandingposition to the horizontal position by the rotating mechanism 72 of thesuction transport mechanism 70 (see FIG. 3). The boat-shaped ribbonplates 14, in the horizontal position, are held on the upper surface ofthe receiving block 80, and are transported in this state to therounding mechanism (3 of FIG. 1).

The capping unit 4 of FIG. 1 is now explained with reference to thedrawings. FIG. 4 is a cross-sectional view for illustrating processsteps schematically showing the operation of the capping unit of thefirst embodiment of the present invention.

Referring to FIG. 4, the capping unit 90 includes a cap supplying unit91, a guide mandrel 93, a shutter 95 and a magnet 95 a mounted inside alower portion of the shutter.

The cap supplying unit 91 is adapted for supplying the cap 96 in anupstanding position for facilitated insertion thereof into the ribbonplate 14 a held by the assembly chuck 10. The cap 96 is inserted to asupply opening 92. The reciprocable shutter 95 supports the four cornersof the cap 96 to maintain the upstanding state of the cap 96 (see FIG.4). The magnet 95 a, mounted to the lower part of the shutter 95,operates for preventing falldown of the cap 96.

The guide mandrel 93 is inserted into an opening of the cap supported bythe shutter. The end part of the guide mandrel is inserted into anopening 97 a of a mandrel 97 of the assembly chuck 10. The guide mandrel93 is used for inserting the cap 96 with its thrusting surface 94 toinsert the cap as the cap is centered with respect to the one side endof the ribbon plate 14 a held by the assembly chuck 10 (see FIG. 4).

Next, the operation of the capping unit 90 is now explained. The cap 96,supplied to the supply opening 92, is supported at its four corners bythe shutter 95. The orientation of the cap 96 is held by the magnet 95 amounted to the lower inner end of the shutter (see FIG. 4A). The guidemandrel 93 then is inserted through the opening of the cap 96 held bythe magnet (see FIG. 4B). The distal end of the guide mandrel 93 isintroduced through the opening 97 a of the mandrel 97 of the assemblychuck 10 at the stand still position. The cap 96 is thrust at itsthrusting surface 94 and inserted thereby into the single side end ofthe ribbon plate held by the assembly chuck 10 FIG. 4C). The guidemandrel 93 then is withdrawn from the opening 97 a of the mandrel 97 andthe supply opening 92 (see FIG. 4D). When the assembly chuck holding thenext (distinct) ribbon plate has been rotated and is at a standstill, asimilar sequence of operations is repeated.

Referring to the drawings, a film cartridge assembling apparatusaccording to a second embodiment of the present invention is nowexplained. FIG. 11 is a plan view schematically showing the structure ofthe film cartridge assembling apparatus according to the secondembodiment of the present invention. FIG. 12 is a cross-sectional view,taken along line X-X′ of FIG. 11, for schematically showing thestructure of the assembly chuck in the film cartridge assemblingapparatus according to the second embodiment of the present invention.FIG. 13 is a front view, looking along the direction of an arrow A ofFIG. 11, schematically showing the operation of the assembly chuck inthe film cartridge assembling apparatus according to the secondembodiment of the present invention. FIG. 14 is a cross-sectional view,taken along line Y-Y′ of FIG. 12, schematically showing the assemblychuck in a film cartridge assembling apparatus and the state of capinsertion onto the mandrel according to the second embodiment of thepresent invention. FIG. 15 is a perspective view for schematicallyshowing the structure of the mandrel and the component of thedischarging mechanism in the film cartridge assembling apparatusaccording to the second embodiment of the present invention. Meanwhile,the mandrel is not shown in FIG. 12 fir simplicity.

This film cartridge assembling apparatus includes an index unit 510, anassembly chuck 520 and a mandrel 530 (see FIG. 11).

The index unit 510 is a unit for transporting the ribbon plate torespective process step units (a ribbon plate inserting unit, a cappingunit, a clinching unit, an acceptable product discharging unit, and aremnant discharging unit; see FIG. 16). The index unit 510 is adaptedfor being rotated about a shaft of rotation lying at right angles to asubstantially horizontal plane. The index unit includes six supports 512at equi-angular intervals, that is every 60°, about the shaft ofrotation (see FIG. 11). The shaft of rotation 511 is coupled to adriving unit, not shown, adapted for intermittently rotating the indexunit at an angular pitch equal to the aforementioned angular interval(see FIG. 11). One assembly chuck 520 is mounted to each support 512 forperforming an opening/closure movement. The mandrel 530 is mountedbetween the respective assembly chucks 520 with its center axisextending substantially horizontally towards the shaft of rotation (seeFIG. 11).

The assembly chuck 520 is a member for holding the cylindrically roundedribbon plate and is formed to have a cylindrically-shaped inner surfacewith a portion of the circumference of the cylinder being cut-out andopened. The assembly chuck 520 includes a haze side chuck 521 and astraight side chuck 522 (see FIG. 12) and holds a haze part 552 of theribbon plate so as to overlie the center axis 540 (on a plumb line ofextension 542).

The haze side chuck 521 includes a cylindrically-shaped surface 521 a,formed on its inner surface, for holding the cylindrical outer side ofthe portion of the ribbon plate extending from the haze part 552 of theribbon plate to its bottom, and an edge member 521 b, having a distalend of the edge facing the straight side chuck 522, and which isadjustably combined with the cylindrically-shaped surface 521 a (seeFIG. 12). The haze part 552 of the ribbon plate is hooked to the edgemember 521 b (see FIG. 12). The edge member 521 b is fixed in ahorizontally adjustable optional position.

The straight side chuck 522 includes a cylindrically-shaped surface 522a, formed on its inner surface, for holding the cylindrical outer sideof the portion of the ribbon plate extending from the straight part 551to its bottom, and a retention member 552 b, having a flat portionextending from an end of the cylindrically-shaped inner surface to theopening, and which is adjustably combined with the cylindrically-shapedsurface 522 a (see FIG. 12). The retention member 552 b is constructedfor extending from one end of the cylindrically-shaped surface 522 a ina manner flush with the one end for retaining the outer surface of thestraight part 551 (see FIG. 12). The retention member 552 b is securedto the plate surface of the straight part 551 at an optional verticallyadjustable position relative to the plate surface thereof (see FIG. 12)

In the closed state of the assembly chuck 520, the inner surfaces of thehaze side chuck 521 and the straight side chuck 522 are matched topresent a cylindrically-shaped inner surface, whereas, in the openedstate of the assembly chuck 520, the ends 521 c, 522 c of the haze sidechuck 521 and the straight side chuck 522 extending substantiallyparallel to the cylindrically-shaped surface of the assembly chuck arespaced away from each other (see FIG. 12). The opening/closure movementsof the haze side chuck 521 and the straight side chuck 522 are bymechanical movements of an opening/closure mechanism 523 (see FIG. 13).The opening/closure mechanism 523 may be different from the illustratedconfiguration.

In a transverse cross-section in the closed state of the assembly chuck520, an angle θ between a line 542 extending from the center axis 540 inthe radial direction and a line 541 interconnecting a boundary linebetween the substantially cylindrical surface and the planar portion(surface abutting against the straight portion of the ribbon plate) ofthe straight side chuck and the center axis is approximately 35° in thesecond embodiment (see FIG. 12). Although the angle θ of 25 to 50°suffices, the angle is preferably 30 to 40°. With the angle θ of 30 to40°, the pull-out torque is well-balanced with light shieldingproperties, thus preventing the yield from being lowered.

The assembly chuck 520 includes a step 520 a on the inner peripheralsurface of the chuck-side distal end of the mandrel 530 for enabling theinsertion of an outer peripheral surface portion 560 a of the cap intothe end of the ribbon plate 550 (see FIG. 14).

The mandrel 530 is a member for holding the ribbon plate 550, inparticular the one-capped cartridge having a cap clinched to its singleside end, in stability, even in the opened state of the assembly chuck520, and is arranged in a space delimited by the cylindrically-shapedinner surface of the assembly chuck 520. The mandrel 530 has an outercylindrically-shaped outer surface smaller than the cylindrically-shapedsurface of the assembly chuck (see FIG. 15).

A magnet 531 for holding a cap 560 by suction is mounted in the vicinityof the distal end face of the mandrel 530 (see FIG. 14). The distal endface of the mandrel 530 has a face 532 matched to the surface of thecap. By holding the cap 560 of the one-capped cartridge by the magnet531, the one-capped cartridge may be held in stability without beingpopped out from the chuck, even when an indexing operation is carriedout at a high speed. The distal end face of the mandrel 530 includes arecess 533 into which is inserted a convexed part 570 a of the guidemandrel for cap insertion in the capping device, not shown, such thatthe cap 560 may be inserted in the centered state to the ribbon plate550. The convexed part is adapted to be inserted into the opening in thecap. The capping device is used for inserting the cap to the single sideend of the ribbon plate when the assembly chuck holding the ribbon platein the cylindrically rounded state is halted at another halt position.

A horizontal guide groove 534 is formed in the cylindrically-shapedsurface of the mandrel 530. In this guide groove is slid a pin 580 a ofa component of a discharging mechanism 580 (see FIG. 15). The componentof a discharging mechanism 580 is a component for ejecting the ribbonplate or the one-capped cartridge comprised of the cap clinched to thesingle side end of the ribbon plate, held by the mandrel 530, when theassembly chucks 521, 522 are in the opened state (see FIG. 13C). Thecomponent of a discharging mechanism 580 is able to thrust the end ofthe ribbon plate by the distal end of the mandrel 530 to eject theribbon plate or the one-capped cartridge from within the assembly chuck.

The operation of the film cartridge manufacturing apparatus of thesecond embodiment is now explained. FIG. 16 is a block diagramschematically showing the structure of the film cartridge manufacturingapparatus of the second embodiment of the present invention.

First, the boat-shaped ribbonplate 550 is supplied from a ribbon platesupply unit 502 to a rounding unit 503. In the rounding unit 503, theboat-shaped ribbon plate, supplied thereto, is rounded to asubstantially cylindrical shape (see FIG. 16).

The rounded ribbon plate is transported from the rounding unit 503through a ribbon plate introducing unit 509 to the assembly chuck 520which is halted in the near-by position. The ribbon plate is introducedinto the assembly chuck 520 which is in the opened state. The assemblychuck 520 then is closed to hold the ribbon plate 550 in thecylindrically rounded state (see FIGS. 12 and 16).

When the index unit 510 is rotated by one pitch and halted in adifferent halt position, a cap is inserted in the capping unit 504 tothe single side end (the distal end side of the mandrel) of the roundedribbon plate 550, held as described above (see FIGS. 14 and 16). At thistime, the assembly chuck 520 does not perform an opening/closuremovement.

When the index unit 510 is rotated by one pitch and halted in adifferent halt position, a clinching claw 590 is thrust in a clinchingunit 505 to the step 520 a of the assembly chuck, from the inner surfaceof the outer rim 560 a of the cap 560, inserted into the ribbon plate,thereby clinching the cap 560 to the ribbon plate 550, to form theone-capped cartridge (see FIGS. 16 and 17). At this time, the assemblychuck 520 again does not perform an opening/closure movement.

When the index unit 510 is rotated by one pitch and halted in adifferent halt position, the inspecting unit 506 monitors the engagedstate between the cap of the produced one-capped cartridge and theribbon plate to detect whether or not the one-capped cartridge isacceptable (see FIG. 16). At this time, the assembly chuck 520 againdoes not perform an opening/closure movement.

When the index unit 510 is rotated by one pitch and halted in adifferent halt position, the assembly chuck 520 is opened in theacceptable product discharging unit 507. Based on the results ofdetection by the inspecting unit 506, the one-capped cartridge, detectedto be acceptable, is thrust by the component of a discharging mechanism580 so as to be discharged to outside (see FIGS. 15 and 16). Theone-capped cartridge, detected to be unacceptable, is not discharged.

When next the index unit 510 is rotated by one pitch and halted in adifferent halt position, the assembly chuck 520 is in the opened state.If there exists the unacceptable one-capped cartridge, the one-cappedcartridges that were not discharged by the acceptable productdischarging unit or remnants (such as single caps or single ribbonplates) 507 are thrust in the unacceptable product discharging unit 508by the component of a discharging mechanism 580 so as to be dischargedto outside (see FIGS. 15 and 16).

When the index unit 510 is rotated by one pitch and halted in adifferent halt position, the ribbon plate, rounded in the rounding unit503, is inserted into the empty assembly chuck 520. The above-describedsequence of operations is repeated (see FIG. 16). The operations in therespective process step units are carried out in parallel such that oneone-capped cartridge is completed for each one-pitch partial rotation.

Referring to the drawings, a third embodiment of the present inventionis explained in detail. FIG. 19 is a partial side view schematicallyshowing the structure of the film cartridge forming apparatus of thethird embodiment of the present invention, and FIG. 20 is a partialfront view schematically showing the structure of he film cartridgeforming apparatus of the third embodiment of the present invention. Itis noted that an uplifting shaft 726 and a roller presser 729 of FIG. 19are shown in cross-section, as in the other figures, and that a framesection 708 is not shown in FIG. 20.

Referring to FIG. 19, this film cartridge forming apparatus is designedfor forming the boat-shaped ribbon plates, supplied one by one, tocylindrically-shaped ribbon plates, and includes a mandrel 701, asupport metal 702, a rounding roller 703, a first arm 704, a presserroller 705, a second arm 706, a guide section 707, a frame section 708,a roller holder 709, a housing 710 and a shaft 711.

The mandrel 701 is a member having a cut-out in its upper surface and acylindrically-shaped surface, and is arranged with its center axishorizontal (see FIG. 19). The portion of the mandrel 701 extending froma clamp section 712 with respect to a support metal 702, that is theribbon plate supply side portion of the mandrel, is formed as a passagesection 713 through which the boat-shaped ribbon plate 750 istransported by a carrier, not shown. It is noted that the surface of theboat-shaped ribbon plate, destined to be the inner surface when theribbon plate is rounded, is to be directed to the mandrel 701. A recess714 (bottomed groove) is formed in the bottom surface of the passagesection 713, and a magnet 715 is mounted near the bottom of the recess714 at a spacing from the bottom surface of the passage section 713,which bottom surface is to be understood as not including the innerlateral surface of the recess. This magnet 715 performs the role ofattracting metal debris affixed to the boat-shaped ribbon plate 750. Thesupport metal 702 is a member for clamping the ribbon plate from itsbottom side in cooperation with the mandrel 701, as the ribbon plate 750is abutted against the mandrel 701, that is as the surface of the ribbonplate destined to be its inner surface, is directed to the mandrel 70l(see FIG. 19). When a roller holder 709 is uplifted by a cam, not shown,the support metal 702 is uplifted by an uplift shaft 726 and a spring728, along with a support member 727, for clamping the ribbon plate bythe force of the spring 728 in cooperation with the mandrel 701 (seeFIG. 20). In the surface of the support metal 702, directed to themandrel 701, there is formed a groove complementary to the curvedsurface of the mandrel 701 (see FIG. 19). The mandrel 701 and thesupport metal 702 are collectively termed a mandrel unit.

A rounding roller 703 is a roller for rounding the ribbon plate 750,clamped by the mandrel unit, as the rounding roller presses the ribbonplate, thus clamped, along the cylindrically-shaped surface section ofthe mandrel 701. A left side rounding roller and a right side roundingroller are arranged as a pair to form the rounding roller 703 and aremounted to the first arm 704 for rotation about a shaft 721 as thecenter of rotation.

A first arm 704 is a member for assisting in the operation of therounding roller 703 through a predetermined range. Actually, a left sidefirst arm and a right side first arm are arranged symmetrically andmounted to a roller holder 709 for performing an oscillatory movementabout shafts 722 as center of oscillation. The portion of the first arm704 towards the mandrel 701 carries the rounding roller 703 for rotationabout a shaft 721 as the center of rotation. The back side of the firstarm carries a cam follower 716 for performing a smooth sliding movementwithin a guide groove 717 of a guide section (see FIG. 19). On the backside of an intermediate trunk section of the first arm 704 (on theopposite side to the mandrel 701) is mounted a roller presser 729 forpressing the rounding roller 703 towards the mandrel 701, moreprecisely, for pressing the back side surface of the intermediate trunksection of the first arm 704 (see FIG. 19). The roller presser 729 ismade up by a presser metal fixture 731 that may emerge from or bereceded into an opening formed in a preset member mounted to the rollerholder 709 and a spring 730 perpetually thrusting the presser metalfixture from its back side (see FIG. 19)

The presser roller 705 is a roller for pressing the cylindrical surfaceon each side of the clamp section for the ribbon plate 750 when theribbon plate is rounded to a cylindrical shape. Actually, a left sidepresser roller and a right side presser roller are arranged in a pairbetween the left and right side first arms 704 and are mounted to thesecond arms 706 for rotation about shafts 723 as the center of rotation(see FIG. 19).

The second arms 706 assist in movement of the presser rollers 705 withina preset range and are arranged symmetrically on the left and rightsides between the left and right first arms 704. The second arms 706 aremounted to the roller holders 709 for oscillation about the shafts 724as the center of oscillation. The presser rollers 705 are mounted forrotation in the vicinity of the mandrel 701 for rotation about theshafts 723 as the center of rotation (see FIG. 19). The first arm 704 iscontacted with the back side of the intermediate trunk section of thesecond arm 706 (the opposite side of the second arm to the mandrel 701)for pressing the presser roller 705 towards the mandrel 701, that is forpressing the back surface of the trunk portion of the second arm 706(see FIG. 19).

The guide section 707 is a member for causing movement of the roundingroller 703 along each outer side of the support metal 702 and along thecylindrically-shaped surface section of the mandrel 701. Actually, aleft side guide section and a right side guide section are arranged in apair and are affixed to the frame section 708. The guide section 707includes a guide groove 717 for guiding the operating direction of thecam follower 716 of the first arm (see FIG. 19).

The frame section 708 is a frame-shaped member secured to the main bodyunit for securing the guide section 707 (see FIG. 19).

In the roller holder 709, the first arms 704 are mounted for oscillationabout the shafts 722 as the center of rotation, while the second arms706 are mounted for oscillation about the shafts 724 as the center ofrotation. Actually, left and right first arms and left and right secondarms are arranged as pairs. The roller holder 709 performs up-and-downmovement, via shafts 711, concomitantly with the up-and-down movement ofthe member 725 (see FIG. 19).

A housing 710 is a mechanical unit for holding a shaft 711, adapted forcausing the up-and-down movement of the overlying roller holder 709,through actuation of a cam, not shown, and through the member 725.Actually, a left side housing and a right side housing are arranged as apair (see FIG. 19)

The shaft 711 is a member for transmitting the up-and-down movement ofthe member 725 to the roller holder 709. Actually, a left side shaft anda right side shaft are arranged as a pair (see FIG. 19).

In the above-described embodiment, a pair of the presser rollers 705 anda pair of the rounding rollers 703 are used. Alternatively, a pluralnumber or a plural number of pairs of the presser rollers or therounding rollers may be used. The rollers may also be formed as one withthe capping/clinching unit.

The operation of the film cartridge manufacturing apparatus of the thirdembodiment is now explained.

Referring first to FIGS. 19 and 20, a boat-shaped ribbon plate 750, withits surface, destined to be the inner surface of the film cartridge,directing towards the mandrel 701, is moved by a carrier, not shown,with the bottom side of the passage section 713 of the mandrel facingthe clamp section 712, as indicated by an arrow. The metal debris thatmay be affixed to the ribbon plate 750 in the course of the movement isattracted by the magnet 715 and thereby removed.

The support metal 702 is opened on its bottom side and the boat-shapedribbon plate 750 transported is inserted by the carrier, not shown, intoa gap between the mandrel 701 and the support metal 702. This supportmetal 702 is then tightened to clamp the boat-shaped ribbon plate 750between the mandrel 701 and the support metal 702 (see FIGS. 19 and 20).

Referring to FIG. 21A, the roller holder 709 is uplifted by the camoperation through shaft 711 to uplift the cam follower 716 of the firstarm 704 along the guide groove 717 of the guide 707 (more precisely,along the plumb line portion thereof), while the rounding roller 703 isuplifted along each of the outer sides of the support metal 702. At thistime, the roller surface of the rounding roller 703 compresses againstthe bottom surface of the boat-shaped ribbon plate 750. Referring toFIG. 21B, the cam follower 716 of the first arm 704 is uplifted alongthe guide groove 717 of the guide 707 (more precisely, along the plumbline portion thereof). During this time, the rounding roller 703 ispressed against the ribbon plate 750 under the action of a presserexemplified by a spring. Thus, the rounding roller 703 is uplifted, asit bends the ribbon plate, until the distance between the center axis ofthe rounding roller 703 and the center axis of the mandrel 701 is equalto the sum of the radius of the rounding roller 703, the radius of themandrel 701 and the thickness of the ribbon plate 750, that is until asurface portion of the ribbon plate 750 registering with thecylindrically-shaped surface of the mandrel 701 is formed.

Referring now to FIG. 21C, as the roller holder 709 is uplifted, therounding roller 703 is moved along the cylindrically-shaped surface ofthe mandrel 701, with the rounding roller pressing thecylindrically-shaped surface of the mandrel 701 by the roller presser.In this manner, the ribbon plate 750 is rounded to a true circularshape. When the pressing roller 705 compresses against each of thelateral sides of the clamp section of the ribbon plate 750, theuplifting of the roller 703 ceases (see FIG. 22).

The trajectory of the rounding roller 703 from FIG. 21B to FIG. 21C atthis time is such that, as the rounding roller 703 is uplifted, the leftand right side rounding rollers 703 are separated away from each otheralong the cylindrically-shaped surface of the mandrel 701. On the otherhand, the trajectory of the rounding roller 703 from FIG. 21C to FIG. 22is such that, as the rounding roller 703 is uplifted, the left and rightside rounding rollers 703 approach to the cylindrically-shaped surfaceof the mandrel 701.

Meanwhile, lacking the operation of the cam follower 716 of the firstarm 704 or the guide groove 717 of the guide section 707, the roundingroller 703, moving at a fast speed, cannot follow up with rollerpressing such that it tends to be displaced from the ribbon plate 750 toproduce a gap (skipping), or otherwise the thrusting pressure againstthe ribbon plate 750 becomes unstable. In the present embodiment, thehigh-speed follow-up of the trajectory of the rounding roller 703 may beassured by the operation of the cam follower 716 of the first arm 704 orthe guide groove 717 of the guide section 707, so that theabove-mentioned problem is not raised.

Referring to FIG. 23, a haze part 751 and a straight part 752 of theribbon plate are retained from both outer lateral sides of the ribbonplate by a retention pawl 740 before the rounding roller 703 and thepresser roller 705 are lowered. Subsequently, the rounding roller 703and the presser roller 705 are lowered by the camming operation of themember 725 to separate the rounding roller 703 and the retention roller705 away from the ribbon plate 750. At this time, the haze part 751 andthe straight part 752 are separated away from each other by theresiliency proper to metal material and are retained by the retentionpawl 740, thus producing a slight gap between the mandrel 701 and theribbon plate 750.

Finally, the ribbon plate 750, rounded around the mandrel 701, is fedout by a feed claw, not shown, from the mandrel 701, as the ribbon plate750 remaining rounded is retained by the retention pawl 740. The ribbonplate, thus fed out, is transported to the next step, such as anassembly chuck.

The meritorious effects of the present invention are summarized asfollows.

With the present invention (method and apparatus for manufacturing filmcartridges), the respective process step units of ribbonplate rounding,cap insertion and cap clinching are carried out simultaneously, thusachieving the high speed operations.

With the present invention (method and apparatus for manufacturing filmcartridges), the respective process steps of ribbon plate rounding, capinsertion and cap clinching are carried out at different sites, so thatthe indexing angles of the driving cams for the respective operationscan be broader and a sudden operation can be smoothed and hence theimpact can be lessened to elongate the useful life.

With the present invention (method and apparatus for manufacturing filmcartridges), the tray is first tilted when transferring the boat-shapedribbon plate from the tray to the stocker, so that no gap is producedbetween the ribbon plates to assure stabilized transferring operations.On the other hand, the lift cylinder of the transfer mechanism with asmaller stroke suffices, while the mechanism for tilting the holdingmeans in the transfer mechanism is unnecessary, thus simplifying themechanism.

Moreover, with the present invention (method and apparatus formanufacturing film cartridges), the ribbon plates can be transported ortaken out in stability in the stocker.

Additionally, with the present invention (method and apparatus forsupplying plate materials), the feed claw does not rub against theribbon plate edge or the coating surface, in the course of the transportof the ribbon plates from the stocker, so that only little debris isproduced.

In accordance with the present invention (film cartridge assemblingapparatus), the entire outer peripheral surface of the ribbon plateincluding the straight portion and the cylindrical surface of therounded ribbon plate is retained by the assembly chuck, and hence theone-capped cartridge can be assembled with the cylindrical surface ofthe rounded ribbon plate being close to the true circle even under highspeed operating conditions. As a result, film grazing due to anon-optimum surface shape is scarcely produced.

Moreover, in accordance with the present invention (film cartridgeassembling apparatus), the angle between the line interconnecting thecenter axis of the assembly chuck and the distal end of the edge memberand the line interconnecting the boundary line between thecylindrically-shaped inner surface and the flat surface and the centeraxis, in the transverse cross-sectional surface in the closed state ofthe assembly chuck, is constant, thus assuring facilitated setting ofthe port width. As a result, the port may be of a constant width todecrease the occurrences of non-optimum light shielding properties.

In addition, in accordance with the present invention (film cartridgeassembling apparatus), it is possible to prevent port width deviationsto eliminate time loss otherwise caused by adjustment, thus assuringstable holding even under high speed operating conditions.

In accordance with the present invention (film cartridge formingapparatus), the track of the rounding rollers are guided by the guidesection (guide mechanism), so that the rounding rollers move stably,formation of polygonal shape of the ribbon plate is prevented and thestable rounding of the ribbon plate under high speed operatingconditions can be carried out.

Moreover, in accordance with the present invention (film cartridgeforming apparatus), because the ribbon plate rounded by the roundingroller is pressed by the presser roller, the intra-stress of the ribbonplate becomes constant, the cross-sectional shape of ribbon plate isnearly perfect circle and the quality of the ribbon plate improveswithout graze on the surface of the ribbon plate.

Further, in accordance with the present invention (film cartridgeforming apparatus), unnecessary movement of the first arm is preventedby the guide section (guide mechanism), so that the maintenance of theapparatus is improved and the period of maintenance can be elongated.

In accordance with the present invention (film cartridge formingapparatus), metal debris attached on the surface of the ribbon plate areabsorbed by the magnet internally mounted to the passage section of theribbon plate before rounding, so that the photographic film accommodatedtherein is protected from the grazing even after producing the filmcartridge.

It should be noted that other objects, features and aspects of thepresent invention will become apparent in the entire disclosure and thatmodifications may be done without departing the gist and scope of thepresent invention as disclosed herein and claimed as appended herewith.

Also it should be noted that any combination of the disclosed and/orclaimed elements, matters and/or items may fall under the modificationsaforementioned.

1. A film cartridge forming apparatus for rounding a ribbon plate of afilm cartridge, having accommodated therein a photographic roll film,said apparatus comprising: a mandrel having a cylindrically-shapedsurface section; a rounding mechanism having a pair of first rollersmounted for rotation for rounding the ribbon plate to a cylindricalshape by said paired first rollers pressing said ribbon plate againstsaid mandrel along said cylindrically-shaped surface section of saidmandrel, as said ribbon plate is moved; and a guide mechanism forguiding operation of said rounding mechanism so that said paired firstrollers are moved along said cylindrically-shaped surface section ofsaid mandrel.
 2. A film cartridge forming apparatus for rounding aribbon plate of a film cartridge, having accommodated therein aphotographic roll film, said apparatus comprising: a mandrel having acylindrically-shaped surface section; a support metal for clamping theribbon plate in cooperation with the mandrel as said ribbon plate iscompressed against the cylindrically-shaped surface section of saidmandrel; a rounding mechanism having a pair of first rollers mounted forrotation for rounding the ribbon plate to a cylindrical shape by saidpaired first rollers pressing both lateral sides of a clamp section forsaid ribbon plate against said mandrel along both outer sides of asupport metal or the cylindrically-shaped surface section of saidmandrel, as said ribbon plate is moved; and a guide mechanism forguiding the operation of said rounding mechanism so that said pairedfirst rollers are moved along said cylindrically-shaped surface sectionof said mandrel.
 3. The film cartridge forming apparatus as defined inclaim 1 wherein said rounding mechanism comprises a pair of secondrollers mounted for rotation, said paired second rollers thrusting thecylindrically-shaped surface section of said ribbon plate when saidribbon plate is rounded by said paired first rollers.
 4. The filmcartridge forming apparatus as defined in claim 1 wherein said guidemechanism presses the ribbon plate with said paired first rollers andguides the operation of said rounding mechanism so that a portion ofsaid ribbon plate is compressed against the cylindrically-shaped surfacesection of said mandrel.
 5. The film cartridge forming apparatus asdefined in claim 1 wherein said guide mechanism comprises a pair of camfollowers operatively associated with said paired first rollers and aguide member having a groove for guiding said paired cam followers sothat said paired first rollers are moved along the cylindrically-shapedsurface section of said mandrel.
 6. The film cartridge forming apparatusas defined in claim 1 comprising a retention pawl for retaining a hazepart and a straight part of the rounded ribbon plate and a feed claw forfeeding out the ribbon plate as said haze part and a straight part ofthe ribbon plate are retained.
 7. The film cartridge forming apparatusas defined in claim 2 wherein said mandrel comprises a passage sectionfor transporting the ribbon plate in a portion thereof extending from aclamp section with said support metal, and a magnet mounted in thevicinity of the bottom of a recess formed in the bottom of said passagesection as said magnet is separated from the bottom of said passagesection.